Modular molding system and methods thereof

ABSTRACT

The present invention relates generally to the field of moldings traditionally used to cover transitions between surfaces or for decoration, and particularly to modular molding systems and methods thereof where molding sections are joined together to produce the desired length of the molding. The present invention is particularly adaptable for use by a do-it-yourself installer or renovator. The present invention and methods allows fast installation and seamless connection of the molding, and in particular, makes the task of installing crown molding easier without requiring specialized carpentry knowledge or experience.

FIELD OF INVENTION

The present invention relates generally to the field of moldings traditionally used to cover transitions between surfaces or for decoration, and particularly to modular molding systems and methods thereof.

BACKGROUND OF THE INVENTION

Molding is generally a strip of material with various cross sections traditionally used to cover transitions between surfaces or for decoration. It is traditionally made from solid milled wood or plaster but may be made from plastic, foam, reformed wood, or other similar and suitable material.

A variety of moldings are commercially available, including crown molding, baseboard molding, and door and window casing. Most of these molding currently on the market, especially crown molding, are difficult to install and require mastery in woodworks and carpentry to produce a visually pleasing decorative molding. A major difficulty with instillation of molding arises in trying to reduce the visibility of seams created by cutting and joining different segments of molding, or when installing pieces of molding around a corner. A favorite type of molding to install is the crown molding, which is typically applied along the seams where the ceiling meets the wall, and this adds a difficulty to the installation process, namely the need for complex cuts to form corners where two walls meet.

Many of the available moldings are not easy to install for do-it-yourself installation and renovation. For molding installation, especially crown molding, an installer must calculate and cut the ends of the crown molding with a miter to create the corners. The traditional way to connect two pieces of molding together is done with a mitered cut on each ends of crown to be connected. One side would have an outer cut and the other side would have an inward cut. Then, one piece of molding is placed next to the other in a way that one mitered end overlaps the other and supports the other piece. Most of the time connecting the two pieces creates a gap between the pieces, which is usually filled with some type of filler, such as wood filler or puddy, which many times will crack over a short period of time, resulting in an unsightly and conspicuous seam to show on the molding.

While there has been a trend to produce more effective moldings and molding systems that are easier to install, further improvements in efficiency, effectiveness, and ease of use for installation of aesthetically pleasing and seamless moldings, especially crown moldings is desirable, and the present invention addresses the existing problems and provides related solutions and benefits.

SUMMARY OF THE INVENTION

The present invention relates generally to the field of moldings or traditionally used to cover transitions between surfaces or for decoration, and particularly to modular molding systems and methods thereof where molding sections are joined together to produce the desired length of the molding. The present invention is particularly adaptable for use by a do-it-yourself installer or renovator. The present invention and method allows fast installation and seamless connection of the molding, and in particular, makes the task of installing crown molding easier without requiring extensive carpentry knowledge or experience. There is no need to calculate and cut the ends of the crown with a miter to create the corners, because ready-made corner pieces can connect to the crown molding on each end and will create the corner and the connection base for the next piece. The only cut that needs to be made is a straight cut on each end in order to attach sections of the molding in order to reach the desired length.

The present invention recognizes that installation of molding, particularly crown molding can be made easier and more efficient and effective in a more visually pleasing way by providing modular molding sections that are able to seamlessly connect with each other.

A first aspect of the present invention includes a modular molding section, including a front face, a back face, a top edge, a bottom edge, a right side, and a left side; and one or more cavity channels running through the entire length of the modular molding section, the one or more cavity channels being capable to receiving one or more connection pins, wherein the one or more cavity channels and the one or more connection pins provide for male-female attachment of two or more of the modular molding sections together.

A second aspect of the present invention includes a method for installing modular molding sections, including the steps of; a) providing a plurality of molding sections including a front face, a back face, a top edge, a bottom edge, a right side, and a left side; b) providing one or more cavity channels running through the entire length of the modular molding sections; c) providing one or more connection pins capable of being partially inserted into the one or more cavity channels; and d) partially inserting the one or more connection pins into the one or more cavity channels of a first section of the modular molding such that an area of the one or more connections pins is partially exposed from the one or more cavity channels; and e) inserting the exposed area of the one or more connection pins of the first section of the modular molding into the cavity channels of a second section of the modular molding, wherein the one or more cavity channels and the one or more connection pins provide for male-female attachment of two or more of the modular molding sections together.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective front view of the present invention including a corner piece attached to a section of a crown molding.

FIG. 2 shows a perspective back view of the present invention including a corner piece attached to a section of a crown molding.

FIG. 3 shows a bird's eye view of the back side of a section of a crown molding.

DETAILED DESCRIPTION OF THE INVENTION Introduction

The present invention recognizes that installation of molding, particularly crown molding can be made easier and more efficient and effective in a more visually pleasing way by providing modular molding sections that are able to seamlessly connect with each othe

As a non-limiting introduction to the breadth of the present invention, the present invention includes several general and useful aspects, including:

1) A modular molding section, including:

-   -   a front face, a back face, a top edge, a bottom edge, a right         side, and a left side; and

one or more cavity channels running through the entire length of the modular molding section, the one or more cavity channels being capable of receiving one or more connection pins, wherein the one or more cavity channels and the one or more connection pins provide for male-female attachment of two or more of the modular molding sections together.

2) A method for installing modular molding sections, including the steps of;

-   -   a) providing a plurality of molding sections including a front         face, a back face, a top edge, a bottom edge, a right side, and         a left side;     -   b) providing one or more cavity channels running through the         entire length of the modular molding sections;     -   c) providing one or more connection pins capable of being         partially inserted into the one or more cavity channels; and     -   d) partially inserting the one or more connection pins into the         one or more cavity channels of a first section of the modular         molding such that an area of the one or more connections pins is         partially exposed from the one or more cavity channels; and     -   e) inserting the exposed area of the one or more connection pins         of the first section of the modular molding into the cavity         channels of a second section of the modular molding, wherein the         one or more cavity channels and the one or more connection pins         provide for male-female attachment of two or more of the modular         molding sections together.

Further objectives and advantages of the present invention will become apparent as the description proceeds and when taken in conjunction with the accompanying drawings. To gain a full appreciation of the scope of the present invention, it will be further recognized that various aspects of the present invention can be combined to make desirable embodiments of the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Where a term is provided in the singular, the inventor also contemplates the plural of that term. The nomenclature used herein and the procedures described below are those well known and commonly employed in the art.

I. Modular Molding System and Methods Thereof

The present invention relates generally to the field of moldings traditionally used to cover transitions between surfaces or for decoration, and particularly to modular molding systems and methods thereof.

The present invention includes a modular molding sections, including a front face, a back face, a top edge, a bottom edge, a right side, and a left side. Decorative moldings are architectural details installed to trim floors, doors, windows, walls, and ceilings. If carefully installed, they can enhance any decor and increase the value of any home. The moldings of the present invention may be made from any suitable material for its purpose, for example, hardwood, soft wood, molded wood product, plastic foam, resin materials, or a combination thereof. Usually, moldings are used to hide shoddy construction, give visual enhancement, or add a period look.

The present invention also includes one or more cavity channels, open tracks running through the entire length of the modular molding sections, the one or more cavity channels being capable of receiving one or more connection pins, wherein the one or more cavity channels and the one or more connection pins provide for male-female attachment of two or more of the modular molding sections together. The one or more cavity channels of the present invention can be in any suitable shape or configuration, for example, circular cavity channels or other shaped cavity channels or open tracks, preferably, and T-notch shaped cavity channels. An important aspect of the present invention is that the one or more cavity channels be made uniform in position with respect to the dimensions of the molding, for example, two cavity channels may be provided through the entire length of an uncut section of the modular molding, wherein the cavity channels are parallel to one another and are also parallel to the top and bottom edges of the modular molding sections in substantially exact distances, such that when the uncut piece of modular molding is cut at any location, it will be able to match exactly to another piece of the modular molding for connection, from the same or a different batch of uncut modular molding sections. The one or more cavity channels run through the length of the entire molding sections to provide for a modular molding.

Preferably the connection pins are partially, about half-way, inserted into the cavity channels of the molding sections at the right and/or left side of the molding sections, such that the connection pins are partially sticking inside the cavity channels and partially sticking out of the cavity channels. The segment of a connection pin that is sticking out of the cavity channel can be inserted into the cavity channel of another section of molding at its side in order to connect the two sections of molding in a very exact manner where the sides of the two molding sections come together forming a substantially seamless modular molding. After the molding is primed, sanded, and painted, the seam between the two molding sections will be essentially invisible to viewers inside the room. The connections pins of the present invention may be made from any suitable material such as wood similar to the same material as the modular molding sections or other suitable material such as metals or non-metals.

The modular molding and methods of the present invention provide for a unique and special connection system designed to easily connect pieces of molding together, such as a section of a crown molding to another section of crown molding. Because the cavity channels are substantially uniform and run through the entire length of the sections of molding, therefore, cutting the molding at any given spot will enable the insertion and attachment of the connection pins inside the cavity channels for attachment of one piece of molding to another. For example, a section of a crown molding may have two cavity channels running through its entire length forming two tracks, and cutting the crown molding at any desired location will reveal the two tracks which provide for two cavity channels where the connection pins can be partially inserted. The partially inserted connecting pins sticking out of the a first section of a crown molding can then be inserted into the tracks of a second piece of crown molding at the proper side that has also been cut at a desired location and thus, connecting the two piece of crown molding together. This system allows connecting two pieces of crown molding to form one uniform and seamless piece of crown molding, with about zero tolerance for any gap to occur at the junction, creating a perfect seam connecting two standard size pieces into one longer piece of crown molding.

The present invention allows for fast and seamless connection of segments of molding, and makes the task of installing molding, especially crown molding, easier without requiring any special carpentry knowledge or experience. The present invention allows for the connection of the desired cuts and number of the modular molding together first, and then installing them at the desired location, or alternatively installing one piece of modular molding at a time as the molding is being installed at the desired location. With the present invention, there is no need to calculate and cut the ends of the crown with a miter to create the corners. Ready-made corner pieces having one or more partially exposed cavity channels, or connection pins sticking out of each side of the corner piece may be used to connect to the molding at each end and creating the corner and the connection base for the next piece of molding to be installed and extended. The only cut that needs to be made is a straight cut on each end of the segment of the molding that is going to be used for attachment to another section of molding. The seamless molding connection methods of the present invention will not only provide a smooth invisible seam, but also allow for a faster and easier method for installation of molding, well suited for the aspiring do-it-yourself home improver or renovator.

Preferably, the modular molding sections of the present invention include one or more cavity channels in the form of T-notch configurations, and the connecting pins are in the shape of rectangles which can fit and be inserted into the top part of the T-notch configured cavity channel. The molding sections may be connected to each other by way of connecting pins that are able to fit tightly, by way of pressure and friction, inside the cavity channel providing adequate means of connection, however, it is preferred that the connecting pins are attached to the cavity channels by way of an adhesive, glue, resin, nail, screw, or other suitable attaching means in order to provide a more secure connection.

EXAMPLES Example I Modular Molding System and Methods Thereof

Referring to FIGS. 1 through 3, this Example provides an embodiment of the modular molding systems and methods thereof in the form of a crown molding. The modular molding section 100, includes a front face 101, a back face 102, a top edge 103, a bottom edge 104, a right side 105, and a left side 106. The modular molding section also includes one or more cavity channels 107 running through the entire length of the modular molding section 100, wherein the one or more cavity channels 107 are capable of receiving one or more connection pins 108, wherein the one or more cavity channels 107 and the one or more connection pins 108 provide for male-female attachment of two or more of the modular molding sections 100 together. In this Example, the modular molding section is shown attached to a ready-made corner piece 109 for the crown molding.

All headings are for the convenience of the reader and should not be used to limit the meaning of the text that follows the heading, unless so specified. Various changes and departures may be made to the present invention without departing from the spirit and scope thereof. Accordingly, it is not intended that the invention be limited to that specifically described in the specification or as illustrated in the drawings, but only as set forth in the claims. Although the invention has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions, and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. 

1. A modular molding section, comprising; a front face, a back face, a top edge, a bottom edge, a right side, and a left side; one or more cavity channels running through the entire length of said modular molding section, said one or more cavity channels being capable of receiving one or more connection pins, wherein said one or more cavity channels and said one or more connection pins provide for male-female attachment of two or more of said modular molding sections together.
 2. The modular molding section of claim 1, wherein said modular molding section comprises two of said cavity channels.
 3. The modular molding section of claim 1, wherein said one or more cavity channels comprise T-notch configuration.
 4. The modular molding section of claim 1, wherein said one or more connection pins is attached to said one or more cavity channels by way of an adhesive.
 6. A method for installing modular molding sections, comprising the steps of; a) providing a plurality of modular molding sections comprising a front face, a back face, a top edge, a bottom edge, a right side, and a left side; b) providing one or more cavity channels running through the entire length of said modular molding sections; c) providing one or more connection pins capable of being partially inserted into said one or more cavity channels; d) partially inserting said one or more connection pins into said one or more cavity channels of a first section of said modular molding such that an area of said one or more connections pins is partially exposed from said one or more cavity channels; and e) inserting said exposed area of said one or more connection pins of said first section of said modular molding into said cavity channels of a second section of said modular molding, wherein said one or more cavity channels and said one or more connection pins provide for male-female attachment of two or more of said modular molding sections together.
 7. The method of claim 6, wherein said modular molding sections comprise two of said cavity channels.
 8. The method of claim 6, wherein said one or more cavity channels comprise T-notch configuration.
 9. The method of claim 6, wherein said one or more connection pins is attached to said one or more cavity channels by way of an adhesive. 